Dual density thermoplastic urethane saddle shoe

ABSTRACT

A golf shoe having a saddle portion for providing lateral support to the foot for increased support during the golf swing. The saddle comprising a base and overlay inserts, each comprising of a thermoplastic urethane (TPU) material of different hardness than the other. The non-stretchable nature of TPU provides an increased level of stability to an area of the foot where lateral strength is crucial. The base having a hardness of less than about 75 Shore A, while the overlay inserts have a hardness of at least about 75 Shore A.

FIELD OF THE INVENTION

[0001] This invention relates to a shoe, optionally a shoe having a thermoplastic urethane saddle across the top of the shoe. More specifically the shoe is a golf shoe with an upper saddle portion of dual hardness.

BACKGROUND OF THE INVENTION

[0002] Golf shoes generally include a shoe upper joined to a midsole to define a chamber for receiving the golfer's foot. The midsole is usually joined to an outsole on an outer surface for interacting with the ground. The inner surface of the midsole is adjacent a footbed that rests within the chamber of the shoe and contacts the wearer's sole. The midsole and footbed provide cushioning for the wearer's foot so they are typically formed of materials that are softer than the outsole material.

[0003] In one round of eighteen holes of golf a golfer may walk about 4 to 5 miles. Over such distances a golfer's health can depend on their shoes as various foot and, less obviously, back problems can be linked to footwear. During this activity, a golfer's performance also depends on the ability of the golfer's shoes to provide a solid base of support and provide necessary cushioning.

[0004] Shoes should be both comfortable and stable. Comfortable shoes are those that allow natural foot movements during walking which means forefoot flexibility and that allow torsion movement between forefoot and the rear of the foot. Golf shoes, in addition to being comfortable, should be rigid in the lateral direction for good stability when hitting the ball. In general, a very comfortable shoe does not provide sufficient support and a very stable shoe may be too stiff and heavy. These competing requirements must be balanced in order to provide the best of both.

[0005] There remains a need for an improved golf shoe that will provide the softness and flexibility in the metatarsial joints (the ball) and stability in the lateral portion so as to provide a good hitting platform.

SUMMARY OF THE INVENTION

[0006] The present invention relates to a shoe upper having a thermoplastic urethane (TPU) saddle portion comprising of dual durometer materials for structural support. The saddle portion includes a base and overlay inserts RF welded onto the base, which provide extra structural integrity to the overall strength of the base. The overlay inserts provide stability and lateral support for the wearer. More importantly, the shoe is used preferably as a golf shoe and the increased lateral support is of critical importance in the golfer's ability to perform a proper golf swing. The hardness of the TPU material of the base is at least 5 Shore A less than the hardness of the TPU material in the overlay inserts.

[0007] In an embodiment of the invention, the hardness of the overlay inserts is at least 75 Shore A and the hardness of the base is no greater than 75 Shore A with a differential hardness of at least 5 Shore A. The TPU material forming the saddle portion is non-stretchable for increased lateral support. The rest of the upper portions are made from relatively soft leather, thereby providing both strength and flexibility required for a walking shoe.

BRIEF DESCRIPTION OF THE DRAWINGS

[0008]FIG. 1 is a perspective view of the shoe with the TPU saddle of the invention.

[0009]FIG. 2 is a side view of the shoe with the TPU saddle.

[0010]FIG. 3 is a top view along a single plane of the base and overlay inserts prior to being placed upon the shoe.

[0011]FIG. 4 is a side view of the TPU saddle.

[0012]FIG. 5 is a top view of the TPU saddle.

[0013]FIG. 6 is a pictorial view depicting the thickness of the inserts upon the base of the TPU saddle.

[0014]FIG. 7 is a bottom view of the gel fusion sole.

DETAILED DESCRIPTION OF THE PREFERED EMBODIMENT

[0015] An embodiment of a golf shoe 10 constructed according to the present invention is shown in FIGS. 1-7. The shoe 10 is one of a pair of shoes, having a left shoe and a right shoe which are mirror images of each other. Each shoe 10 includes an upper 12, a midsole 14 joined to the upper 12, and an outsole 16 joined to the midsole 14. The upper 12 has a generally conventional shape and is comprised of a saddle section 18, a vamp portion 20, a quarter portion 22 and a heel support portion 24. The saddle section 18 has a toe end 26 and a heel end 28, with the toe end 26 attached to the vamp portion 20 and the heel end 28 attached to the quarter portion 22. The saddle section 18 is comprised of a base 30 having a top surface 31 and overlay inserts 32 that are formed upon the top surface 31 of the base 30, preferably by radio frequency welding. The top portion of the upper 12 forms an opening 34 to receive a wearer's foot. Upper 12 is preferably secured to midsole 14 with cement or other adhesives using an insole board and conventional techniques, as known by those of ordinary skill in the art. The outsole 16 includes a torsion management system as disclosed in co-pending application Ser. No. 10/190,974, which is hereby incorporated by reference in its entirety.

[0016] The midsole 14 provides cushioning to the wearer, and is formed of a material such as an ethylene vinyl acetate copolymer (EVA). Preferably, the midsole 14 is formed on and about the outsole 16. Alternatively, the midsole 14 can be formed separately from the outsole 16 and joined thereto by such as adhesive. Once the midsole 14 and outsole 16 are joined, the outsole 16 forms a substantial portion of the bottom of shoe 10.

[0017] Referring to FIGS. 1-6, the upper 12 includes the saddle section 18 formed on suitable upper material, such as leather or the like. Leather provides the shoe with the durability, yet softness and flexibility required for walking. The saddle section 18 is made from molded dual durometer thermoplastic urethane (TPU) materials. The non-stretchable nature of TPU provides the shoe with the integrity and lateral stability necessary for proper support during the golf swing. The overlay inserts 32 provide the base 30 with structural reinforcement and additional stability in the saddle section 18 of the shoe 10.

[0018] The base 30 has a different hardness than the overlay inserts 32. Preferably the overlay inserts 32 are at least about 5 Shore A harder than the base 30. The overlay inserts 32 preferably have a hardness of at least about 75 Shore A, preferably about 80A, while the base 30 has a hardness preferably equal to or less than 75 Shore A. The overlay inserts 32 have a thickness that is greater than the thickness t of the base as best depicted by FIG. 6.

[0019] Referring to FIG. 7, one preferred mechanism for providing the torsional movement of the outsole 16 is a connector 36 and a male member 38. The male member 38 extends from the forward edge of a shank-heel portion of the rear foot section 40 and forms a ball-and-socket joint with the connector 36 which is located in the forefoot section 42. The ball and socket connection provides a pivot that allows for natural rotation between the forefoot section 42 and rear foot section 40 during walking and during a golf swing. In a preferred embodiment the pivot point P is located between the midfoot and forefoot, preferably just behind the transverse arch at the intersection of the subtalar joint axis and the midtarsal. The overlay inserts 32 of the saddle section 18 are coupled to the midsole 14 at a position rearward (towards the heel) of the pivot point P to provide lateral stability yet not detract from the torsional management of the outsole 16 which allows for independent movement between heel and forefoot sections.

[0020] While it is apparent that the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that modifications and other embodiments may be devised by those skilled in the art. It is intended that the appended claims cover all such modifications and embodiments as fall within the true spirit and scope of the present invention. 

It is claimed:
 1. A shoe comprising: an upper having a saddle section attached thereon; the saddle section having a base with a top surface; overlay inserts mounted to the top surface of the base; and the base having a hardness different than the overlay inserts.
 2. The shoe of claim 1, wherein the base and overlay inserts are made from non-stretchable materials.
 3. The shoe of claim 1, wherein the overlay inserts are mounted to the base by radio frequency welding.
 4. The shoe according to claim 1, wherein the hardness of the overlay inserts is at least about 5 points higher than the hardness of the base.
 5. The shoe according to claim 1, wherein the overlay inserts are comprised of a material having a hardness of at least about 75 Shore A.
 6. The shoe according to claim 1, wherein the base comprises a material having a hardness equal to or less than 75 Shore A.
 7. The shoe of claim 1, wherein the shoe is a golf shoe.
 8. The shoe of claim 1, wherein the shoe further comprises; a midsole with a heel section and a forefoot section; and the overlay inserts are coupled to midsole at heel section.
 9. A saddle golf shoe, the saddle comprising: a base the base having a top surface; overlay inserts mounted to the top surface of the base; and the overlay inserts having a hardness different than the base.
 10. The shoe of claim 9, wherein the base and overlay inserts are made from urethane materials.
 11. The shoe of claim 9, wherein the inserts are attached to the base by radio frequency welding.
 12. The shoe according to claim 9, wherein the hardness of the overlay inserts is at least about 5 points higher than the hardness of the base.
 13. The shoe according to claim 9, wherein the overlay inserts are comprised of a material having a hardness greater than about 75 Shore A.
 14. The shoe according to claim 9, wherein the base comprises a material having a hardness of about 75 Shore A or less.
 15. A shoe comprising: an upper, an outsole and a midsole interconnecting the upper to the outsole; the upper having a saddle section comprising a base with overlay inserts mounted to a top surface of the base; the outsole having a pivot point connecting forefoot and rearfoot sections; and the overlay inserts coupled to the midsole at a point rearward of the pivot point.
 16. The shoe according to claim 15, wherein the hardness of the overlay inserts is about 5 points higher than the hardness of the base.
 17. The shoe according to claim 16, wherein the overlay inserts are comprised of a material having a hardness of at least about 80 Shore A.
 18. The shoe according to claim 16, wherein the base comprises a material having a hardness equal to or less than 75 Shore A. 